This summer I bought a ktm 640 adventure [IMG]file:///C:/Users/SERGIU%7E1.GIU/AppData/Local/Temp/msohtmlclip1/01/clip_image001.gif[/IMG]. After riding all summer, i decided that this bike is a keeper so, as winter is coming i'm planning a general rebuild. The previous owner rode the bike for about 50 k and had done some improvements, also an engine rebuild about 10 k ago. As i was surfing the net for bits and pieces to prepare for the project, I came across a 2003 ktm duke 2 barely used with some cosmetic problems so i decided to get it as a donor bike for the adventure.

The plan is this:
- use the duke engine (that comes with a hydraulic clutch and high flow cylinder head) after water pump rebuild and valve check
- check and replace (if needed) all bearings
- front and rear suspension service (haven't decided i will try to do it myself or send them to a specialist)
- use the duke electrical wiring (the one from the adventure is bye bye )
- powder coat the frame black
- paint the entire bike (i was thinking also black but open to suggestions )
And the list continues on and on but more during the build [IMG]file:///C:/Users/SERGIU%7E1.GIU/AppData/Local/Temp/msohtmlclip1/01/clip_image001.gif[/IMG]
As soon as i will figure out how, i will post some photos.

And now some questions:

The new duke engine makes a ticking noise when rpm is very low, the previous owner said it is the automatic decompressor, is it true?
I mounted a trailtech vapor kit on the adventure and connected the power wire directly to the battery, and the wire is now toast - do you have idea why?
Are the duke headlights better than the adventure ones ? (the adventure headlight are an old petrol lamp [IMG]file:///C:/Users/SERGIU%7E1.GIU/AppData/Local/Temp/msohtmlclip1/01/clip_image002.gif[/IMG])

Any other suggestions are welcome!

Here are some more picture of the strip down:

This is the home made front-end that i intend to reuse, but with some mods

Ticking/clacking sound at low RPM is the auto decompression system. Idle should be set at a high enough RPM (+_1800) so the auto decom. doesn't kick in and make the sound. You should hear the same sound when you shut the motor off, just before it stops.

Ticking/clacking sound at low RPM is the auto decompression system. Idle should be set at a high enough RPM (+_1800) so the auto decom. doesn't kick in and make the sound. You should hear the same sound when you shut the motor off, just before it stops.

Yep, & it will be much louder on a low km's motor - the mechanism is probably getting a little worn & quieter on your 640 adv.

Cheers
Clint

__________________'03 KTM 640 LC4 Enduro

The wilderness, the desert - why are they not crowded.................................................. .....with pilgrims?

So this weekend I got around to finish the whole disassembly on both the bikes and I’m going to send of the frame and the rest of the parts for powder coating. Here is a question: can I powder coat the aluminium rims? The heat from the oven won’t damage them?
Regarding the headlight I decided to go with the duke assembly as the duke bulbs are 65W compared to the 55 w adventure.
I’m sorry there are no picture, but I forgot my camera at home and the garage is about 20 km outside the city – this is why I can work only weekends .

now for the interesting part to begin. The front fairing is home made by the previous owner and altough it's a lot better looking and mode practical than the original one, i think there is room for improvement. So i asked my father to send me the grinder, and after a 15 hour train trip it was in my hands ready to do some damage
As i had the duke front lying around i decided to use this as a donor. If i could manage to use the duke lamp, i would have better light (65w instead of 55) more compact and light mounting system and a perfect fit to the duke electrical wire that i intend to use, so let's cut away
Architect style - no measurements

The guy that makes my stickers made me very happy the past day se below why :

So the rebuild is turning out to be veeeeeeeeery slow with no chance of ending before march I think....
For now I’ve sent of the frame and other metal parts that need welding to be done, and after that I will be sending them to powder coating. I what to make an upgrade to my center stand, so if you know the dimensions and angles in the sketch below, please let me know.

The welding is almost finished, the only thing left is the center stand. If anyone could measure and tell me the dimensions for a b c and d in the picture above, that would be GREAT . I now realize that I should have done this before striping the bike, but now it’s too late ..